ON THE COVER: The cover features a Laser Induced Breakdown Spectrometer (LIBS) designed to measure insitu and in real time the concentration of trace elements in melts and feedstocks. The image on the left 

shows a schematic of the system planned for use in an aluminum melt, while that on the right shows the 

LIBS system actually at work in a melt at a Commonwealth Aluminum plant, in Ulrichsville, Ohio. The 

system was devised and developed by Energy Research Company, ERCO, Staten Island, NY. This project was 

completed in fiscal year 2004. 

In operation, a pulsed laser is focused through a fiber-optic cable into a molten aluminum sample, 

generating high-temperature plasma. As the plasma cools, it radiates light at specific wavelengths 

corresponding to elemental constituents of the melt. The strengths of the emissions are related to the 

concentration of each of the elemental constituents. A significant accomplishment has been the 

development of software for the analysis of the LIBS signal that provides elemental concentrations without 

the need to calibrate for the elements sought. 

Currently, elemental analysis is conducted by periodically grabbing a molten sample and taking it to a lab 

for analysis. This is expensive and time-consuming, and it does not allow real-time control. By allowing insitu, real-time measurement of melt constituents, this technology will improve product quality and allow 

continuous operations, thus saving energy. Energy-savings are projected to be 8.3 trillion Btu annually by 

2020. ERCO is also applying the technology to the glass, steel and utility areas. 
Industrial Technologies Program — Boosting the Productivity and 

Competitiveness of U.S. Industry 

Industry consumes 33 percent of all energy used in the United States. By developing and adopting more 

energy efficiency technologies, U.S. industry can boost its productivity and competitiveness while 

strengthening national energy security, improving the environment, and reducing emissions linked to global 

climate change. 

The U.S. Department of Energy’s (DOE) Office of Energy Efficiency and Renewable Energy (EERE) works in 

partnership with U.S. industry to increase the efficiency of energy and materials use, both now and in the 

future. EERE’s Industrial Technologies Program (ITP) is working to build the Industries of the Future through 

a coordinated program of research and development (R&D), validation, and dissemination of energy 

efficiency technologies and operating practices to reduce energy intensity in the industrial sector. ITP 

develops, manages, and implements a balanced portfolio that addresses industry requirements throughout 

the technology development cycle. The primary long-term strategy is to invest in high-risk, high-return R&D. 

Investments are focused on technologies and practices that provide clear public benefit but for which market 

barriers prevent adequate private sector investment. 

ITP focuses its resources on a small number of energy-intensive materials and process industries that account 

for over 55 percent of industrial energy consumption. 

• Aluminum 

• Chemicals 

• Forest Products 

• Glass 

• Metal Casting 

• Mining 

• Steel 

ITP uses a leveraging strategy that maximizes the energy and environmental benefits of its process-specific 

technology investments by coordinating and cooperating with energy-intensive industries. By working 

closely with the private sector, ITP is able to effectively plan and implement comprehensive R&D agendas and 

help disseminate and share best energy management practices throughout the United States. ITP publicprivate partnerships also facilitate voluntary efforts, such as the President’s Climate VISION initiative, to 

encourage industry and government to reduce greenhouse gas emissions. 

ITP also conducts R&D projects on enabling technologies that are common to many industrial processes such 

as industrial energy systems, combustion, materials, and sensors and process control systems. In addition, 

ITP funds technical assistance activities to stimulate near-term adoption of best energy-saving technologies 

and practices within industry. These activities include plant assessments, tool development and training, 

information dissemination, and showcase demonstrations. 

New technologies that use energy efficiently also lower emissions and improve productivity. By leveraging 

technical and financial resources of industry and government, the ITP partnerships have generated 

significant energy and environmental improvements that benefit the nation and America’s businesses. 

Energy-intensive industries face enormous competitive pressures that make it difficult to make the necessary 

R&D investments in technology to ensure future efficiency gains. Without a sustained commitment by the 

private and public sectors to invest in new technology R&D and deployment, the ability to close the gap 

between U.S. energy supply and demand will be severely compromised. 

CONTENTS 

Executive Summary ............................................................................................................................................ i


Overview of Industrial Measurement and Control ......................................................................................... 1


Energy Use .......................................................................................................................................................... 1


The Challenge ..................................................................................................................................................... 2


Key R&D Pathways ............................................................................................................................................. 2


FY 2004 Highlights & Accomplishments .......................................................................................................... 5


R&D Highlights .................................................................................................................................................... 5


Partnership Highlights ......................................................................................................................................... 7


Improving Energy Efficiency Today ..................................................................................................................... 7


Disseminating Research Results to Industry ........................................................................................................ 8


Energy Analysis – Targeting Energy Efficiency ....................................................................................................8


Tools, Publications, and Resources Available ................................................................................................... 9


How To Get Involved and Contact Information ............................................................................................ 10


Partnership Information ................................................................................................................................... 10


Access to Resources and Expertise....................................................................................................................... 10


Where to Go for More Information .................................................................................................................. 11


EXHIBITS 

1. Energy Footprint of the U.S. Industrial Sector ............................................................................................. 1


2. Sensors and Automation Targets ................................................................................................................... 2


3. R&D Pathways for the Five Sensors & Automation Focus Areas ................................................................... 3


4. Key Energy-Saving Opportunities Identified in a Recent S&A Study ........................................................... 4


5. Active Sensors & Automation Projects in FY 2004 ........................................................................................ 5


6. Phase II SBIR Projects Managed by S&A in FY 2004...................................................................................... 5


7. Examples of Other ITP Projects Relevant to Sensors & Automation ............................................................. 6

EXECUTIVE SUMMARY 

A Successful Partnership with Industry 

Sensors and control systems are integral components of virtually every industrial process. Intelligent control 

systems and process automation help manufacturers improve plant energy efficiency and boost productivity 

by increasing throughput, yield and product quality. Other benefits include enhanced worker safety, 

increased production flexibility and reduced generation of waste products and pollutants. 

The U.S. Department of Energy’s (DOE) Office of Energy Efficiency and Renewable Energy (EERE) leads the 

federal role in developing advanced energy-efficient and environmentally friendly industrial technologies. 

Crosscutting R&D in sensors and automation is a component of the overall EERE strategy and contributes to 

the goals outlined in the National Energy Policy. Advanced sensors and controls can provide data that 

enable an operator to consistently optimize production processes. Measurement and control systems that 

permit continuous process operation will aid industry in its push for higher productivity and efficiency. For 

example, real-time process monitoring and control systems will enable higher quality products from highspeed, precision forming operations, reducing the amount of rejected product that must be reworked. 

The EERE Industrial Technologies Program directs the Sensors & Automation (S&A) portfolio, which seeks to 

increase the energy efficiency of energy-intensive industrial processes by investing in the development of 

technologies that are applicable in multiple industries. S&A collaborates with other ITP portfolios to create 

technologies that address some of the most pressing fundamental measurement and control needs facing 

industry today. This collaboration allows S&A to leverage its resources while helping to develop a core set of 

enabling technologies for energy-intensive industries. S&A supports projects that address the broad sensor, 

control and automation priority needs identified in the ITP’s industrial portfolios’ technology roadmaps. 

A Successful Strategy with Industry 

DOE’s Office of Energy Efficiency and Renewable Energy leads federal development of advanced energyefficient and environmentally friendly industrial technologies. Sensors and Automation R&D is a 

component of the overall EERE strategy, contributing to a reduction in energy intensity of industry, a goal 

outlined in the National Energy Policy. 

EERE/ITP is working to build the Industries of the Future through a strategy that is based on multi-year 

planning, industry involvement and input during the planning process, and careful analysis and data-based 

decision making. This strategy not only takes into consideration the interests of the industry as described in 

their R&D Technology Roadmaps, but also consists of an agenda of analytical studies that provide the basis 

for decision making. For instance, the Analysis of Sensors, Controls, Automation, and Robotics Needs in the IOF 

Technology Roadmaps published in 2003, has provided the basis for focusing the R&D by identifying industry 

research interests. The Assessment Study on Control Systems, Information Processing, Automation, and Robotics in 

the IOFs and Analysis of Crosscutting Potential of ITP Sensor Technologies were developed using both government 

and industry data and information, and industry expertise to provide the next level of prioritization for the 

portfolio. By using these studies, the portfolio is able to design a multi-year R&D plan based on the focus 

area, barrier, and pathway approach. In this approach, a limited number of critical technology focus areas 

are identified along with the technical barriers preventing their successful implementation. A multi-year 

plan (called a “Pathway”) is then developed that will guide the R&D activities leading to a successful 

development of the focus area technology. The “Pathways” are then the basis for solicitations of precompetitive R&D that addresses both energy efficiency goals outlined in the National Energy Policy and 

industry research priorities. This successful strategy has now evolved, providing focus on potentially highimpact research to make revolutionary improvements in sensors and automation. 

Achieving Energy Savings: Sensors & Automation Strategy 

The Sensors & Automation activity supports a diverse portfolio of cost-shared, crosscutting research 

addressing technological needs that have broad applicability throughout the industrial sector. S&A leads ITP 

in providing advanced measurement and control technology solutions to meet the needs of all industry 

sectors supported by the IOF strategy. 

i 
The goal of ITP’s Sensors & Automation portfolio is to identify, develop and deploy integrated measurement 

systems for operator-independent control of manufacturing processes that can be used by more than one industry 

and are fully compatible with the harsh industrial environment. Ultimately, systems will enable a level of 

productivity and quality currently unattainable under human or machine control and produce a 5 percent gain 

in energy efficiency. 

S&A’s research is focused on advanced sensor technologies, next-generation controls and automation, 

improved information processing, robotics and affordable wireless technologies. The portfolio directly 

supported 10 projects in FY 2004 and also co-directed other projects in some of the other industrial ITP 

portfolios. S&A is also responsible for a number of Small Business Innovation Research (SBIR) projects in the 

sensors and control area. More information about the Sensors & Automation portfolio is available on the 

ITP Web site at http://www.eere.energy.gov/sensors_automation/portfolio.html. 

FY 2004 Highlights 

• In-Situ, Real-Time Measurement of Melt Constituents – A laser-induced breakdown spectroscopy 

technology that measures melt constituents in-situ and in real time has been successfully tested at a 

Commonwealth Aluminum plant. Marketing of this new technology is underway and two commercial 

sales have already occurred. Additional applications now being investigated with other funding include 

the glass, steel, and utility (coal-burning power plants) industries. 

• Solid State Sensor for Monitoring Hydrogen – A solid-state sensor (developed with DOE cost-sharing two 

years ago) that rapidly detects a wide range of concentrations of hydrogen gas has been modified by 

project partner Air Products and is now marketed by small business H2scan. The new unit replaces more 

costly mass spectrometer units; hundreds of units were sold in FY 2004 to a variety of industries. 

• Tunable Diode Laser for Harsh Combustion Environments – A tunable diode laser sensor for detecting 

temperature, NOX levels and CO levels in harsh furnace environments has been successfully tested at the 

pilot scale. In FY 2004, the technology was upgraded for use in steel industry electric arc furnace 

applications, and preliminary field tests have been initiated. 

• Fiber-Optic Sensor for Industrial Process Measurement and Control – A prototype tunable diode laser 

absorption spectroscopy instrument for practical use in measuring temperature and chemical composition 

in combustion applications has been successfully tested with an industrial combustor and an industrial 

chemical vapor deposition torch. Additional demonstrations are planned for steam methane reforming, a 

coal-fired power plant application and a boiler simulator. 

• Broadly Tunable Mid-Infrared Hydrocarbon Sensor – Researchers have developed a broadly tunable, midinfrared laser spectrometer that can be used in the petrochemical industry for species concentration 

measurement (particularly propylene, ethylene and methane). Preliminary efforts leading to construction 

and testing of a prototype portable gas analyzer were completed in FY 2004. 

• Cavity-enhanced Gas Analyzer for Process Control Applications –An ultra-sensitive, cavity-enhanced 

absorption cell has been developed as an alternative to gas chromatography for measuring acetylene 

contamination during ethylene production. Numerous other applications have been identified in 

industrial process control and environmental monitoring; meanwhile, commercialization efforts are 

underway. 

• Advanced Wireless Sensors for the Industries of the Future – The DOE Extreme Measurement 

Communications Center (EMC2

) located at Oak Ridge National Laboratory was constructed and made 

operational. Developers of wireless technologies will be able to use this center to ensure that their 

technologies have suitable robustness, latency, throughput and security for deployment in the industrial 

sector. 

ii 
• Support for the Creation of WINA – S&A assisted suppliers and end-users of industrial wireless technology 

with the creation of WINA, the Wireless Industrial Networking Alliance. WINA’s major objective is to 

promote the adoption of wireless networking technologies and practices that will help increase industrial 

productivity and efficiency. In February 2004, S&A assisted in facilitating the first WINA General Assembly. 

In June 2004, more than 450 people signed up to attend a WINA seminar held during the Sensors Expo in 

Detroit. 

iii 
OVERVIEW OF INDUSTRIAL MEASUREMENT AND CONTROL 

Measurement and control systems are integral components of virtually every industrial process and are 

essential to the proper operation and profitability of most industries. Intelligent control systems and process 

automation help manufacturers improve plant energy efficiency and boost productivity by increasing 

throughput, yield and product quality. These technologies also increase the flexibility of production 

processes while reducing their impact on the environment and enhancing worker safety. 

The United States is both the largest provider of and the largest single national market for measurement and 

control products and services. Approximately 1,000 manufacturers and distributors of sensor and control 

equipment currently exist in this country. Total employment of these companies exceeds 50,000, with a 

payroll of more than $2 billion per year. The market for process controls is valued annually at approximately 

$26 billion worldwide; the total value of U.S. shipments was $9 billion in 2002, with process industries 

accounting for about 70 percent (more than $6 billion). 

Energy Use 

Industrial energy end-use patterns can be illustrated through the use of an energy footprint. The footprint 

shown in Exhibit 1 demonstrates that energy delivered is lost prior to being used in specific processes. Close 

to 3,000 trillion Btus (3 quads) of energy are lost in energy conversion processes (e.g., process heating 

equipment, motors) and an unknown additional amount is lost in manufacturing processes. These are the 

areas in which Sensors & Automation can help industry make meaningful gains in energy efficiency. 

Exhibit 1


Energy Footprint of the U.S. Industrial Sector


Industrial Plant Boundary 

Process energy losses 

from waste heat, flared 

gases, by-products 

TBD 

U.S. Manufacturing Energy Footprint: 

24658 Trillion Btu 

Energy 

Supply 

17762 

•Fuels 

•Purchased 

Electricity 

and Steam 

Energy Losses 

Utility/ 

Power 

Plant 

3102 

Process Energy Systems 

Energy Conversion 

13561 

• Process Heating (10649) 

(heat exchangers, condensers, fired 

heaters, heat pumps) 

• Process Cooling/ 

Refrigeration (255) 

• Electrochemical (346) 

• Machine Drives (2074) 

(pumps, compressors, fans, blowers, 

conveyors, mixers) 

• Onsite Transport (118) 

• Other (119) 

Central Energy 

Generation/ 

Utilities 7774 

• Steam Plant 

(4934) 

• Fossil Power 

(463) 

• Renewable Power 

(12) 

• Direct Fuel Supply 

(7864) 

• Purchased 

Electricity (3102) 

Energy 

Distribution 

16375 

• Steam Piping 

• Fuel Piping 

• Transmission Lines 

Energy Export 79 

Recycle Energy 

Recycle Energy 

By-product fuels and 

feedstocks, heat 

Steam, 

heat 

Facilities/HVAC/Lighting 1405 

Energy Losses 

Losses in boilers and 

electricity generation 

losses 1399 

Losses in pipes, valves, 

traps, electrical 

transmission lines 1330 

Losses due to equipment 

inefficiency (motors, 

mechanical drive, waste 

heat) 2862 Electricity 

generation and 

transmission 

losses 6444 

Distribution 

losses 440 

Fossil 

Energy 

Supply 

14660 

Solar/Geo/

thermal/Wind 

Energy 12 

Process 

Energy Use 

10699 

• Separations 

• Furnaces 

• Melters 

• Reactors 

• Electrolytic Cells 

• Drying 

• Mixing/Grinding 

• Forming 

• Fabrication 

• Energy Storage 

• Waste Handling 

1

1
THE CHALLENGE 

The entire manufacturing industry needs intelligent control systems to improve their resource efficiency and 

product quality and to minimize generation of waste and pollutants. The economic impact of measurement 

and control technology products reaches beyond the industry sectors where these products are applied. 

S&A leads ITP in providing advanced measurement and control technology solutions to meet the needs of all 

industry sectors supported by the ITP portfolio strategy. The goal of the Sensors & Automation portfolio is to 

identify, develop and deploy integrated measurement systems for operator-independent control of 

manufacturing processes that can be used by more than one industry and are fully compatible with the 

harsh industrial environment. Ultimately, systems will enable a level of productivity and quality currently 

unattainable under human or machine control and produce a gain of 5 percent in energy efficiency. 

Many challenges exist in developing advanced measurement and intelligent control systems that meet enduser manufacturers’ needs. These challenges relate to performance characteristics of the technologies, as well 

as their adoption by industry. 

• proven operational reliability and sustained performance in harsh environments 

• robustness and general utility 

• real-time capability and the need for faster and more discriminating sensors to take advantage of today’s 

processing power 

• value to the customer and payback period 

• physical size 

• invulnerability to interference and security (for wireless technologies) 

• awareness of the value of sensor data, particularly in preventing unplanned maintenance 

• awareness that sensors can give greater capabilities to older equipment, thereby decreasing maintenance 

costs 

Key R&D Pathways 

Sensors & Automation directly sponsors the development of integrated measurement systems for operatorindependent control of manufacturing processes with broad applicability across multiple industry sectors. 

S&A also collaborates with the industrial ITP portfolios to co-fund sensors and controls research for these 

industries. 

The roadmaps of the 

seven Industries of the 

Future identify improved 

sensors and controls as 

one of the highest priority 

industry needs for 

increasing manufacturing 

energy efficiency. The 

projects supported by S&A 

address the broad sensor, 

control and automation 

priority needs identified 

in the ITP industrial 

technology roadmaps. 

Over the last several years, 

an increased emphasis has 

been placed on projects to 

develop sensor, controls 

and automation 

technologies capable of 

revolutionizing the 

2 

Exhibit 2


Sensors & Automation Targets


Advanced Sensor 

Technologies 

Next Generation 

Control and 

Automation 

Improved 

Information 

Processing Robotics 

Affordable 

Wireless 

Technologies 

Online, real-time 

high speed 

measurement 

Analytical and physical 

property measurement 

Diagnostic and 

maintenance 

Control and 

Optimization 

Automation 

Model-based control 

Hierarchical and 

plant-wide 

optimization systems 

Advanced numerical 

processing 

Methods to provide 

expanded info from 

easily measured data 

Improved predictive 

capability, modeling, 

simulations, and imaging 

Integration with 

control systems and 

information processing 

More energy-efficient 

robots for industrial 

applications 

Entire 

manufacturing 

process controlled 

using wireless 

sensors, 

controls and 

actuators 

2010 Energy Benefits -- 12 trillion Btu savings per year 

2010 Environmental Benefits -- 0.24 MMTCe reduction in carbon emissions per year 
manufacturing processes 

used by the IOFs, 

thereby saving even 

more energy. 

The S&A research 

portfolio can be 

organized into five 

focus areas: advanced 

sensor technologies, 

next-generation control 

and automation 

technologies, improved 

information processing, 

robotics, and affordable 

wireless technologies. 

Exhibit 2 presents major 

opportunities or targets 

for each of these focus 

areas. Exhibit 3 shows 

the R&D pathways that 

ITP has identified for 

achieving the targets. 

Available resources 

currently limit active 

Exhibit 3


R&D Pathways for the Five Sensors and Automation Focus Areas


S&A ocus Area R&D Pathways

Advanced Sensor 

Technologies 

Next-Generation Control 

and Automation 

Improved Information 

Processing 

Robotics 

Affordable Wireless 

Technologies 

Develop model-based control and predictive control 

Develop hierarchical and plant-wide optimization systems 

Automate the sense-infer-act lopp to achieve operator-independent plant 

optimization 

Develop means for data acquisition, transformation into useful information, 

and use the information for improved process design, operation, energy 

minimization, and quality control 

Integrate/incorporate sensors, information processing, and control systems 

into robotic systems 

Redesign production line with robots to solve long-standing production 

problems 

Redesign robots to increase efficiency 

Evaluate candidate industrial wireless sensor systems in test facility 

Select best technologies for in-plant testing 

Measure performance of motors using wireless systems 

Investigate power harvesting techniques 

Make sensors compatible with the harsh industrial environment 

Increase sensor capabilities; make them real-time, on-line, non-intrusive 

Development, lab testing, host site evaluation 

F

S&A involvement in all focus areas. 

The “Affordable Wireless Technologies” focus area is relatively new and has received increased emphasis in 

the past two years. Wireless sensor systems hold the potential to help U.S. industry use energy and materials 

more efficiently, lower production costs and increase productivity. During FY 2003, DOE published the vision 

document Industrial Wireless Technology for the 21st Century. In line with this vision, the goal of DOE’s 

industrial wireless initiative is to develop a non-proprietary, open architecture wireless network and evaluate 

the network in an industrial production facility. This network will replace the wires now used in sensor and 

control systems and will allow operational approaches that are not practical at this time, such as ubiquitous 

sensing. The target markets of this technology include the ITP industrial portfolios, as well as other 

manufacturing industries. Three new wireless technology projects were begun in FY 2004 and several projects 

to develop power sources for wireless systems were selected as part of an SBIR initiative. S&A’s wireless R&D 

activities were recognized in the April 26th, 2004 issue of Business Week. 

Projects in S&A’s portfolio typically run three to five years and are cost-shared by the technology developer 

(private research companies, technology suppliers and universities). A steering committee comprised of 

representatives from the IOFs and other experts provides direction and guidance. In FY 2004, S&A had 10 

active projects and managed seven SBIR projects. 

In addition to supporting new concepts (such as wireless technology) for next-generation sensors and 

automation, S&A works with the various ITP industrial portfolios to improve existing systems, both industryspecific and cross-cutting. This strategy ensures that the portfolio will help meet the measurement and 

control needs of the ITP portfolios without neglecting the development of fundamentally new concepts that 

could revolutionize how measurement and control functions are performed throughout the industrial sector. 

In line with this new strategy, S&A awarded a total of $16 million over five years to five new crosscutting 

sensors and controls research projects in FY 2004. With the required minimum 50 percent non-federal costshare, the total value of projects undertaken could reach $33 million. 

In March 2004, Sensors & Automation participated in an ITP-wide peer review to solicit comments from 

stakeholders on the focus and direction of the program’s activities. The feedback received on the S&A 

portfolio was generally positive, with particular note of their breadth and cross-cutting nature. It was noted 

that this portfolio has produced a relatively large number of commercial successes since its inception during 

FY 1999. 

3 
To ensure broad participation, S&A’s solicitations are announced in trade society publications, Web sites, and 

meetings, the Commerce Business Daily, FedBizOpps and the Sensors & Automation Web site. Selection of 

projects follows merit-based criteria that emphasize projected energy, environmental and economic benefits 

based on sound analysis using a standardized procedure available in the online Project Evaluation Tool 

(http://www.energetics.com/sensorstool). This rigorous solicitation development and implementation process 

ensures targeted, competitive solicitations for pre-competitive R&D. 

In FY 2004, S&A completed a broad analysis of the current state of the art in controls, automation, robotics 

and information processing (the sensors area was the focus of a similar study conducted in FY 2002) to 

further refine its strategy and identify the best industrial research opportunities for S&A in these four areas. 

The overall effort was comprised of expert study teams working independently in each of the four areas, 

coordinated by Dr. Frank Doyle of the University of California at Santa Barbara. The opportunities 

identified in the study are shown in Exhibit 4. 

Exhibit 4


Key Energy-Saving Opportunities Identified in a Recent S&A Study


Information Processing 

 Integrated plant control 

 Real-time control of energy use 

 Intelligent control 

 Estimation key quality variables 

 Control of particle processes 

 Better model predictive control 

 Automated production 

lines with real time 

quality control 

 Automated 

maintenance and 

diagnostics for 

production equipment 

 Energy-efficient robots 

 Labor robots 

 Extreme-temp robots 

 Predict product quality using process data 

 Monitor and regulate process energy use 

 Determine causes of product and process problems 

Process Control Systems 

Robotics 

Sensor stems 

IOF Production 

Processes 

Raw Material Product 

Process Automation 

Sy

4
FY 2004 HIGHLIGHTS AND ACCOMPLISHMENTS 

Sensors & Automation supports a diverse portfolio of cost-shared research Fact sheets describing projects in the


that addresses high-risk, high-impact needs that have a broad application Sensors & Automation portfolio are


throughout multiple industries. In FY 2004, S&A’s portfolio included 10 located on the DOE/ITP Web site at http://


active projects, one of which was completed that year (see Exhibit 5, which www.eere.energy.gov/industry/


also indicates the prime contractor performing the research and the relevant sensors_automation.


IOFs). S&A also directed three Phase II Small Business Innovation Research (SBIR) grant projects (Exhibit 6).


In addition, over 40 projects in the areas of sensors and controls that are funded by other ITP IOFs are


shown in Exhibit 7. 

Sensors & Automation achieved a number 

of noteworthy accomplishments in FY 2004 

(described below). 

R&D Highlights 

In-Situ, Real-Time Measurement of Melt 

Constituents – Energy Research Company 

has developed a laser-induced breakdown 

spectroscopy technology that measures melt 

constituents in-situ and in real time. The 

technology, which was developed for use in 

the recycled aluminum industry, accurately 

measures the melt composition at any point 

in the melt. A full-scale commercial 

installation at a Commonwealth Aluminum 

facility has been completed and Energy 

Research is continuing its commercialization 

efforts. Solios Thermal has been granted a 

license to market the system worldwide to 

the aluminum industry and two commercial 

sales have already been made. Energy 

Research is also looking at applications in 

the glass, steel and utility industries. 

Solid State Sensor for Monitoring 

Hydrogen – A solid state sensor for 

measuring hydrogen content of gaseous 

streams was developed by Penn State using 

Sandia National Laboratories’ technology 

with DOE co-funding in FY 2003. The 

sensor was then further improved by Air 

Products and is now sold by small business 

H2scan. Users report that the performance 

of the $3,500 unit is equivalent to that of 

Exhibit 5


Active Sensors & Automation Projects in FY 2004


• In-Situ, Real-Time Measurement of Melt Constituents in the Aluminum, Glass, and 

Steel Industries; Prime: Energy Research Company (http://www.eere.energy.gov/ 

industry/sensors_automation/pdfs/libs.pdf) 

• Diagnosis and Control of Natural Gas-Fired Furnaces via Flame Image Analysis*; Prime: 

University of Missouri at Rolla (http://www.eere.energy.gov/industry/sensors_automation/ 

pdfs/flame.pdf) 

• Remote Automatic Material Online Sensor (Forest Products); Prime: Quantum 

Magnetics (http://www.eere.energy.gov/industry/sensors_automation/pdfs/online.pdf) 

• Tunable Diode Lasers Sensors for Monitoring and Control of Harsh Combustion 

Environments; Prime: American Air Liquide (http://www.eere.energy.gov/industry/ 

sensors_automation/pdfs/aal.pdf) 

• Advanced Wireless Sensors for the Industries of the Future (Steel, Aluminum, Mining, 

Glass, Chemicals, Forest Products, Metal Casting, Petroleum Refining); Prime: ORNL 

(http://www.eere.energy.gov/industry/sensors_automation/pdfs/ornl.pdf) 

• Eaton Wireless Sensor Network for Advanced Energy Management Solutions (Steel, 

Aluminum, Mining, Glass, Chemicals, Forest Products, Metal Casting, Petroleum 

Refining); Prime: Eaton (http://www.eere.energy.gov/industry/sensors_automation/pdfs/ 

eaton_wireless.pdf) 

• Distributed Wireless Multisensor Technologies - A Novel Approach to Reducing Motor 

Energy Usage (Steel, Aluminum, Mining, Glass, Chemicals, Forest Products, Metal 

Casting, Petroleum Refining); Prime: General Electric Global Research (http:// 

www.eere.energy.gov/industry/sensors_automation/pdfs/dist_wireless.pdf) 

• Wireless and Sensing Solutions Advancing Industrial Efficiency (Steel, Aluminum, 

Chemicals, Petroleum Refining); Prime: Honeywell International (http:// 

www.eere.energy.gov/industry/sensors_automation/pdfs/honeywell_wireless.pdf) 

• SQA: Surface Quality Assured Steel Bar Program (Steel); Prime: OG Technologies 

(http://www.eere.energy.gov/industry/sensors_automation/pdfs/sqa_surface.pdf) 

* Project was successfully completed in FY 2004 

the $150,000 mass spectrometer system now used. Exhibit 6 

Hundreds of units are now being used to measure the Phase II SBIR Projects Managed by S&A in FY 2004 hydrogen content of gas streams over the 0.5 to 99 

percent range under the demanding conditions of • Fiber-Optic Sensor for Industrial Process Measurement and Control 

hydrogen production and use, as well as to detect (Chemicals, Combustion Applications) (http://www.eere.energy.gov/ 

hydrogen leaks. industry/sensors_automation/pdfs/fiber_optic.pdf) 

• Cavity-enhanced Gas Analyzer for Process Control Applications (Chemicals, 

Tunable Diode Laser for Harsh Combustion Petroleum Refining) 

Environments – American Air Liquide has developed


a tunable diode laser sensor for monitoring key • Broadly Tunable Mid-Infrared Hydrocarbon Sensor (Chemicals) (fact sheet)


5
Exhibit 7


Examples of Other ITP Projects Relevant to Sensors & Automation


Aluminum Projects Metal Casting Projects 

• Intelligent Potroom Operation • In-Situ Real-Time Monitoring and Control of Mold Making and Filling 

• Automotive Aluminum Scrap Sorting Processes 

Chemicals Projects Mining Projects 

• Development of In-Situ Analysis for the Chemical Industry • Horizon Sensing 

• Automated Machine Fluid Analysis System 

Forest Products Projects • High-Temperature Superconductors in Underground Communications 

• Wireless Microwave Wood Moisture Measurement System for Wood Drying • Imaging Ahead of Mining 

Kilns • Real-Time Coal/Ore Grade Sensor 

• Guided Acoustic Wave Monitoring of Corrosion and Erosion in Recovery Boiler • Wireless Mine-Wide Telecommunications 

Tubing • Development of New Geophysical Techniques/Mineral Explorations and 

• Online Fluidics Controlled Headbox Mineral Discriminator 

• Contact-less Real-Time Monitoring of Paper Mechanical Properties • Investigating GPS/IMU Positioning System for Mining Equipment 

• Implementation of an Advanced Quality Control System at a Newsprint • Demonstration of Crosswell Imaging Technology and Advanced Drillstring 

Manufacturing Plant Radar Navigation for Horizontal Directional Drilling 

• Development of Prototype Electrokinetic Sonic Amplitude System for • Effective Conveyor Belt Inspection for Improving Mining Productivity 

Measurement of Zeta Potential • Robot-Human Control Interactions in Mining Operations 

• Online SAG Mill Grinding Pulse Measurement and Optimization 

Glass Projects 

• Measurement and Control of Glass Feedstocks Steel Projects 

• Monitoring and Control of Alkali Volitization and Batch Carryover • Automated Steel Cleanliness Analysis Tool 

• Controlled Thermomechanical Processing of Tubes and Pipes 

combustion species (CO, O2 and H2O) and gas temperature in industrial furnaces. The non-intrusive nature 

of the technology is ideally suited for harsh, high-temperature environments with corrosive gases and/or 

high levels of particulate matter. The data from the new sensor will help furnace operators optimize their 

combustion processes, thereby increasing efficiency and reducing emissions of criteria pollutants and CO2. 

The technology has already been demonstrated in a steel reheat furnace and an aluminum reverberatory 

furnace and is currently being upgraded for use in electric arc steelmaking furnaces. 

Advanced Wireless Sensors for the Industries of the Future – Oak Ridge National Laboratory (ORNL) is 

facilitating the deployment of wireless technologies to industry by demonstrating that the critical issues (e.g., 

reliability, security, robustness) are being addressed by the developers. In FY 2004, ORNL commissioned the 

DOE Extreme Measurement Communications Center (EMC2) to characterize and simulate the performance of 

candidate industrial wireless telemetry devices in harsh industrial environments. 

Wireless Sensor Network for Advanced Energy Management Solutions – Eaton Corporation has initiated 

an effort to research, develop, test and deploy a self-configuring wireless sensor network that operates within 

a range of open wireless protocols and integrates with advanced energy management software. The first 

phase of this project will include development of a baseline system to demonstrate the feasibility of the 

networking concepts. The goal is to use wireless technology to enable electrical distribution and power 

control systems within a plant to communicate and report diagnostic information. 

Distributed Wireless Multisensor Technologies – In this new FY 2004 project, General Electric Global 

Research and its partners seek to bring the benefits of continuous monitoring to smaller (less than 1,000 hp) 

motors through the development of low-cost, distributed wireless sensors. Continuous monitoring should 

allow industries to better maintain and improve the efficiency of their electric motors. Initial technical 

efforts are focusing on characterization of the manufacturing RF environment and identifying and adapting 

wireless technology. 

Wireless and Sensing Solutions Advancing Industrial Efficiency – This new project, led by Honeywell 

International, consists of two separate efforts: the development of a wireless network for secure industrial 

applications and the development of innovative technology for sampling and composition analysis of 

gaseous and liquid process streams. Upcoming activities include demonstration of the security and reliability 

of multiple independent wireless components and the development and lab testing of a gaseous stream 

analyzer that is sufficiently rugged for industrial applications. 

6
SQATM: Surface Quality Assured Steel Bar Program – OG Technologies has initiated research that seeks to 

alleviate surface quality problems in special quality steel bars and rods. The new Surface Quality Assurance 

program will automatically and accurately mark residual surface defects for downstream removal using OG’s 

HotEyeTM technology to deliver high-definition images of workpieces at or exceeding 1,450oC. Research is 

currently focused on improving the accuracy of the in-line surface detection system. 

Fiber-Optic Sensor for Industrial Process Measurement and Control – In Phase II of an SBIR project, 

MetroLaser, Inc. has developed a new commercial temperature and chemical sensor primarily for hightemperature gas combustion measurement and process control applications. The system uses tunable diode 

laser absorption spectroscopy, making it less intrusive and more accurate and flexible than currently used 

extractive sampling techniques. MetroLaser has successfully demonstrated temperature measurement in the 

hot gases and flames of industrial combustors. Additional tests will be conducted in three applications – 

steam methane reforming, a coal-fired power plant and a boiler simulator – and MetroLaser has signed a 

North American distributorship agreement with Bergmans Mechatronics, LLC to market this technology. 

Broadly Tunable Mid-IR Hydrocarbon Sensor – This SBIR Phase II project is developing a broadly tunable 

mid-infrared laser spectrometer that can be used to make rapid, onsite measurements of industrial gases in 

the petrochemical and other industries. Physical Sciences Inc., together with Dow Chemical and Analytical 

Specialties, Inc., is developing this system as an alternative to gas chromatography, which does not allow 

real-time process control. Activities in FY 2004 focused on fabricating key components of the system, 

including the laser source and preparing for the fabrication of a portable prototype analyzer. 

Cavity-enhanced Gas Analyzer for Process Control Applications – Los Gatos Research is developing an 

alternative to gas chromatography for measuring acetylene contamination during ethylene production in 

this Phase II SBIR project. The heart of the new analyzer is an ultra-sensitive, cavity-enhanced absorption 

cell that will permit petrochemical manufacturers to incorporate real-time control, saving millions of dollars 

per year. Dow Chemical Company has been providing both laboratory and field testing of the analyzer and 

has validated its sensitivity, time response, and longevity. Additional applications in measuring emissions 

from engines, oil drilling, and semiconductor manufacturing are being considered, as are potential 

opportunities in military and medical markets. The first commercial units of the new technology are 

expected to be sold by the end of 2004. 

Partnership Highlights 

Wireless Industrial Networking Alliance – Sensors & Automation is assisting suppliers and end-users of 

industrial wireless technology with the creation of WINA, the Wireless Industrial Networking Alliance. This 

alliance emerged from DOE-sponsored wireless technology activities in FY 2003, including the publication of 

Industrial Wireless Technology for the 21st Century, a unified vision for the future of this rapidly evolving 

technology. WINA’s major objective is to promote the adoption of wireless networking technologies and 

practices that will help increase industrial productivity and efficiency. In February 2004, S&A assisted WINA 

in conducting the first WINA General Assembly held in Research Triangle Park, North Carolina, attended by 

more than 60 end-users, suppliers, and system integrators. S&A also provided support to heavily attended 

WINA seminars held in conjunction with Sensors Expo 2004 and ISA Expo 2004. 

International Forum on Process Analytical Chemistry – The annual International Forum on Process 

Analytical Chemistry (IFPAC) is considered the foremost conference in process analysis and technology. 

IFPAC-2004, held in January in Arlington, Virginia, included an entire session devoted to presentations on 

ITP-sponsored research in sensors and controls. The Forum was attended by hundreds of representatives 

from the chemical and pharmaceutical industries, as well as the commercial vendor community. 

Improving Energy Efficiency Today 

Technology Delivery Program – Sensors & Automation focuses on mid- to long-term technology research. 

EERE/ITP’s Technology Delivery Program offers other products and services to assist industry in saving energy 

in the near-term. These products and services include software tools and associated training to improve the 

efficiency of plant utility systems, cost-shared plant assessments, no-cost plant audits for small and mid-size 

7
companies and numerous helpful publications describing applications of good plant operating practices. 

Activities such as these have the potential to save U.S. industry millions of dollars annually. To learn more, 

please visit http://www.oit.doe.gov/bestpractices. For more information on the no-cost audits, please visit 

http://www.oit.doe.gov/iac. 

Disseminating Research Results to Industry 

Sensors & Automation Website – The Sensors & Automation Web site is a valuable tool for disseminating 

information on the portfolio’s activities. The Web site highlights R&D projects, provides access to EERE 

publications and notes upcoming solicitations. The Web site also contains a “News” section that provides 

articles on recent events, updates on research successes and notifications of new software tools and other 

services of relevant interest to manufacturers and users of sensor and control systems technology. It also 

includes contractor presentations from the most recent annual portfolio review meetings. The S&A Web site 

was updated in FY 2004 as part of an ITP-wide redesign project. 

Energy Analysis – Targeting Energy Efficiency 

Sensors & Automation Project Evaluation Tool – An interactive software tool was created to help applicants 

to Sensors & Automation solicitations analyze the potential energy and environmental benefits of their 

technologies. This online tool allows for standardized analysis of the proposed projects, which facilitates 

selection of the best technologies for funding. Applicants to S&A solicitations are now required to use the 

tool. 

GPRA Analysis – This annual exercise was completed for projects considered in the FY 2006 budget. The 

GPRA analysis estimates future benefits of emerging technologies in the Sensors & Automation portfolio 

based on market penetrations, energy savings and environmental emission reductions. 

Assessment Study on Sensors & Automation in the Industries of the Future – Teams of experts in the areas 

of controls, automation, robotics and information processing have conducted broad analyses of the state of 

the art in these four areas, which are of great interest to S&A. The results of the study, which was completed 

in FY 2004, includes lists of the top energy-saving R&D opportunities in each area, the industrial sectors with 

the greatest needs and estimates of the potential energy savings that could be achieved. The study will help 

guide S&A in soliciting proposals for funding projects that could have the greatest impact on reducing 

industrial energy consumption. 

8
TOOLS, PUBLICATIONS, AND RESOURCES AVAILABLE 

EERE offers valuable tools and publications to help companies improve productivity and energy efficiency. 

Some of these resources are described below. View the Web site at http://www.eere.energy.gov/industry/ 

sensors_automation for a complete listing. 

Fact Sheets – Publications describing R&D projects, emerging technologies and commercial successes are 

available on the Web site. 

Industrial Wireless Technology for the 21st Century – Over 30 individuals representing the extended 

industrial wireless community have cooperatively developed a unified vision for the future of this rapidly 

evolving technology. The vision document defines specific goals and challenges, provides some context for 

non-experts and maps out the key hurdles to fully take advantage of wireless capabilities in industrial 

environments. 

Project Evaluation Tool – Software is available at http://www.energetics.com/sensor_tool that can be used to 

estimate the potential energy and environmental benefits of a proposed new measurement or control 

technology. 

Corporate Brochure – The EERE/ITP corporate brochure, Results for Today, Leadership for Tomorrow, provides 

an overview of ITP and the collaborations, partnerships, tools, resources and opportunities available to the 

nation’s essential, energy-intensive industries. The brochure and similar overview publications can be found 

at http://www.eere.energy.gov/about/brochures.html. 

9
HOW TO GET INVOLVED AND CONTACT INFORMATION 

Partnership Information 

Public-private partnerships are the foundation of ITP’s technology delivery strategy. ITP includes its partners 

in every phase of the technology development process to focus scarce resources where they can have the 

greatest impact on industrial energy efficiency. To learn more, please visit our Web site at http:// 

www.eere.energy.gov/industry. 

•	 Collaborative, cost-shared research and development projects are a central part of ITP’s strategy. Annual 

solicitations provide technology development opportunities in a variety of energy-intensive industries. 

•	 Industries of the Future Partnerships increase energy efficiency in the most energy-intensive industries. In 

addition to cost-shared research and development projects, industry partners participate in the 

development of vision and roadmap documents that define long-term goals, technology challenges, and 

research priorities. 

•	 Allied Partnerships provide an opportunity for ITP to reach a broad audience of potential customers by 

allying with corporations, trade associations, equipment manufacturers, utilities, and other stakeholders 

to distribute industrial energy efficiency products and services. By becoming an Allied Partner, an 

organization can increase its value to clients by helping them achieve plant efficiencies. 

•	 State energy organizations work with ITP in applying technology to assist their local industries. ITP 

assists states in developing partnerships to mobilize local industries and other stakeholders to improve 

energy efficiency through best practices, energy assessments, and collaborative research and development. 

•	 EERE’s technical programs (of which ITP is one of 11) give manufacturers access to a diverse portfolio of 

energy efficiency and renewable energy technologies and bring advanced manufacturing technology to 

the renewable energy community. For more information, access the EERE home page at http:// 

www.eere.energy.gov. 

•	 The President’s Climate VISION (Voluntary Innovative Sector Initiatives: Opportunities Now) effort also 

offers opportunities for manufacturers to pursue cost-effective actions that will reduce greenhouse gas 

emissions. See http://www.climatevision.gov for details. 

Access to Resources and Expertise 

The Industrial Technologies Program provides manufacturers with a wide variety of industrial energy 

efficiency resources to help your company cut energy use right away. Visit our site at http:// 

www.eere.energy.gov/ industry or call the EERE Information Center at 877-337-3463 to access these resources 

and for more information. 

•	 ITP offers energy management best practices to improve energy efficiency throughout plant operations. 

Improvements to industrial systems such as compressed air, motors, process heat, and steam can yield 

enormous savings with little or no capital investment. 

•	 Our suite of powerful system optimization software tools can help plants identify and analyze energysaving opportunities in a variety of systems. 

•	 Training sessions are held several times per year at sites across the country for companies interested in 

implementing energy-saving projects in their facilities. DOE software tools are used as part of the training 

sessions. 

•	 ITP’s qualified industrial energy specialists will work with your plant personnel to identify savings 

opportunities and train staff in the use of ITP software tools. 

10
•	 Our extensive library of publications gives companies the resources they need to achieve immediate 

energy savings. 

•	 Plant-wide energy assessments are available to manufacturers of all sizes interested in cutting their energy 

use. Cost-shared solicitations are available each year for plant-wide energy assessments. In addition, nocost, targeted assessments are provided to eligible facilities by teams of engineering faculty and students 

from 26 university-based Industrial Assessment Centers around the country. 

•	 The DOE Regional Offices provide a nation-wide network of capabilities for implementing ITP’s 

technology delivery strategy. Regional Offices are located in the Southeast, Northeast, Midwest, Central, 

Mid-Atlantic, and Western regions. Visit http://www.eere.energy.gov/rso.html for more information. 

Where to Go For More Information 

Visit our Web site: http://www.eere.energy.gov/industry/sensors_automation/ 

Learn about all EERE programs: http://www.eere.energy.gov 

EERE Information Center answers questions on EERE’s products, services and 11 technology programs, refers 

callers to the most appropriate EERE resources, and refers qualified callers to the appropriate expert networks. 

You may contact the EERE Information Center by calling 1-877-EERE-INF (1-877-337-3463) or by completing 

the form at this site: http://www.eere.energy.gov/informationcenter. A customer service specialist or energy 

expert at the EERE Information Center will respond to your inquiry. 

For print copies of DOE, EERE and ITP Publications, contact the


Energy Efficiency and Renewable Energy Information Center


P.O. Box 43165


Olympia, WA 98504-3165


http://www.eere.energy.gov/informationcenter/


For questions regarding Sensors & Automation portfolio activities, please contact: 

Gideon Varga


Industrial Technologies Program


Office of Energy Efficiency and Renewable Energy


EE-2F


U.S. Department of Energy


1000 Independence Avenue, SW


Washington, DC 20585-0121


Phone: 202-586-0082


Fax: 202-586-7114


Email: Gideon.Varga@ee.doe.gov


11
A Strong Energy Portfolio for a Strong America 

Energy efficiency and clean, renewable energy will mean a stronger economy, a cleaner environment, and great energy 

independence for America. By investing in technology breakthroughs today, our nation can look forward to a more 

resilient economy and secure future. 

Far-reaching technology changes will be essential to America’s energy future. Working with a wide array of state, 

community, industry, and university partners, the U.S. Department of Energy’s Office of Energy Efficiency and 

Renewable Energy invests in a portfolio of energy technologies that will: 

• Conserve energy in the residential, commercial, industrial, government, and transportation sectors 

• Increase and diversify energy supply, with a focus on renewable domestic sources 

• Upgrade our national energy infrastructure 

• Facilitate the emergence of hydrogen technologies as a vital new “energy carrier” 

The Opportunities 

Biomass Program 

Using domestic, plant-derived resources to meet our fuel, power, and chemical needs 

Building Technologies Program 

Homes, schools, and businesses that use less energy, cost less to operate, and ultimately, generate as much power as 

they use 

Distributed Energy & Electric Reliability Program 

A more reliable energy infrastructure and reduced need for new power plants 

Federal Energy Management Program 

Leading by example, saving energy and taxpayer dollars in federal facilities 

FreedomCAR & Vehicle Technologies Program 

Less dependence on foreign oil, and eventual transition to an emissions-free, petroleum-free vehicle 

Geothermal Technologies Program 

Tapping the Earth’s energy to meet our heat and power needs 

Hydrogen, Fuel Cells & Infrastructure Technologies Program 

Paving the way toward a hydrogen economy and net-zero carbon energy future 

Industrial Technologies Program 

Boosting the productivity and competitiveness of U.S. industry through improvements in energy and environmental 

performance 

Solar Energy Technology Program 

Utilizing the sun’s natural energy to generate electricity and provide water and space heating 

Weatherization & Intergovernmental Program 

Accelerating the use of today’s best energy-efficient and renewable technologies in homes, communities, and 

business 

Wind & Hydropower Technologies Program 

Harnessing America’s abundant natural resources for clean power generation 

To learn more, visit www.eere.energy.gov 

Sensors & Automation 

Industrial Technologies Program 

Boosting the productivity and competitiveness of U.S. industry 

published February 2005